Download Lennox International Inc. G60UH(X) Series User's Manual

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E 2003 Lennox Industries Inc.
Dallas, Texas, USA
504,781M
6/2003
G60UH(X)
SERIES
GAS FURNACE
Litho U.S.A.
WARNING
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exactĆ
ly could result in serious injury, death,
or property damage.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other apĆ
pliance.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
06/03
*2P0603*
WHAT TO DO IF YOU SMELL GAS:
D Do not try to light any appliance.
D Do not touch any electrical switch; do not
use any phone in your building.
D Leave the building immediately.
D Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
D If you cannot reach your gas supplier, call
the fire department.
504,781M
*P504781M*
G60UH(X) Parts Identification
DURALOKTM HEAT
EXCHANGER
ASSEMBLY
TOP CAP
COMBUSTION AIR
PROVING
(PRESSURE)
SWITCH
FLUE
COLLAR
CABINET
COMBUSTION AIR
INDUCER
GAS
VALVE
UPPER ACCESS
PANEL
GAS
MANIFOLD
BURNERS
TWO-STAGE,
SURELIGHT®
INTEGRATED
CONTROL BOARD
BLOWER
MOTOR
BLOWER ACCESS
PANEL
CONTROL BOX
FIGURE 1
WARNING
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
cancer. (Fiberglass wool is known to the State of CalĆ
ifornia to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact your
supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379-9900
NOTE - This manual must be left with the equipment
user.
Page 2
Do not set thermostat below 60°F (16°C) in heating
mode. Setting thermostat below 60°F (16°C) reduces
the number of heating cycles. Damage to the unit
may occur that is not covered by the warranty.
WARNING
If overheating occurs or if gas supply fails to shut off,
shut off the manual gas valve to the appliance before
shutting off electrical supply.
CAUTION
Before attempting to perform any service or mainteĆ
nance, turn the electrical power to unit OFF at the
disconnect switch.
WARNING
Do not use this furnace if any part has been underĆ
water. A flood-damaged furnace is extremely danĆ
gerous. Attempts to use the furnace can result in
fire or explosion. Immediately call a qualified serĆ
vice technician to inspect the furnace and to replace
all gas controls, control system parts, and electrical
parts that have been wet or to replace the furnace,
if deemed necessary.
IMPORTANT
Any additions, changes, or conversions required in
order for the appliance to satisfactorily meet the apĆ
plication needs must be made by a Lennox service
technician using factory specified and approved
parts.
WARNING
The blower access panel must be securely in place
when the blower and burners are operating. Gas
fumes, which could contain carbon monoxide, can
be drawn into living space resulting in personal injuĆ
ry or death.
Your furnace is a gas appliance. It is critical that the gas
supplied to the unit be completely burned to avoid the proĆ
duction of carbon monoxide gas. Complete combustion of
the gas requires, but is not limited to, correct gas pressure
and gas flow rate, adequate combustion air and proper
venting.
WARNING
Carbon monoxide gas is invisible, odorless, and
toxic.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personĆ
al injury or loss of life. Installation and service must
be performed by a qualified installer, service agency
or the gas supplier.
Safety Instructions
1 - Keep the furnace area clear and free of combustible
material, gasoline, and other flammable vapors and
liquids. If it is installed in an insulated area, the furnace
must be kept free of insulating material. Insulating maĆ
terial may be combustible.
2 - DO NOT obstruct air flow to unit. Unit must receive an
unobstructed flow of combustion and ventilating air.
DO NOT block or obstruct air openings on the furnace
or air openings to the area in which the furnace is
installed. Take care to maintain established clearĆ
ances surrounding the furnace.
3 - DO NOT store chlorine or fluorine products near unit
or introduce these products into the combustion air.
These products can cause furnace corrosion.
4 - DO NOT draw return air from a room where this furĆ
nace, or any other gas appliance (ie., a water heatĆ
er), is installed. When return air is drawn from a room,
a negative pressure is created in the room. If a gas apĆ
pliance is operating in a room with negative pressure,
the flue products can be pulled back down the vent
pipe and into the room. This reverse flow of the flue
gas may result in incomplete combustion and the
formation of carbon monoxide gas. This toxic gas
might then be distributed throughout the house by the
furnace duct system.
Page 3
Exposure to carbon monoxide gas can cause personal injuĆ
ry and even death to all occupants, including pets. Any item
that is powered by, or gives off heat from, a combustion proĆ
cess (including lawn mowers, automobiles, and fireplaces)
has the potential to produce carbon monoxide gas. Because
of this, Lennox recommends the use of a carbon monoxĆ
ide detector in your home, even if you do not own gas
appliances. Reliable detectors are available at reasonable
retail prices. Contact your Lennox dealer for more details
about this investment in your safety.
Your furnace is designed to meet standards set by nationĆ
al agencies. It should operate safely when properly
installed and maintained. However, the unit's perforĆ
mance can be greatly impacted by the individual installaĆ
tion and the operating environment. It is your responsibilĆ
ity to ensure that this appliance is maintained. Proper
maintenance is critical for your safety and the satisfactory
operation of the product. Lennox strongly recommends
annual inspection and maintenance of this appliance.
Contact your Lennox dealer for an inspection by a qualiĆ
fied service technician.
Lighting Information & Operation
WARNING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or death.
BEFORE LIGHTING smell all around the appliance area
for gas. Be sure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
The gas valve on the G60UH(X) is equipped with either a
gas control knob or lever. Use only your hand to turn the
gas control knob or push the gas lever. Never use tools. If
the knob or lever will not move by hand, do not try to repair
it. Call a qualified service technician. Force or attempted
repair may result in a fire or explosion.
Honeywell VR8205 Gas Valve - Turn knob on gas valve
counterclockwise
to ON. Do not force. See figure 4.
WHITE RODGERS 36E SERIES GAS VALVE
Placing the G60UH(X) furnace into operation:
G60UH(X) units are equipped with a SureLight® ignition
system. Do not attempt to manually light burners on these
furnaces. Each time the thermostat calls for heat, the burnĆ
ers will automatically light. The ignitor does not get hot
when there is no call for heat on units with the SureLight®
ignition system.
GAS VALVE SHOWN IN OFF POSITION
FIGURE 3
HONEYWELL VR8205 SERIES GAS VALVE
Operating the Gas Valve (Figures 3 and 4)
1 - STOP! Read the safety information at the beginning of
this section.
2 - Set the thermostat to the lowest setting. See figure 2.
3 - Turn off all electrical power to the unit.
THERMOSTATS
GAS VALVE SHOWN IN OFF POSITION
FIGURE 4
9 - Replace the upper access panel.
10 - Turn on all electrical power to to the unit.
11 - Set the thermostat to desired setting.
FIGURE 2
4 - This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
5 - Remove the upper access panel.
6 - White Rodgers 36E Gas Valve - Switch gas valve leĆ
ver to OFF. See figure 3.
Honeywell VR8205 Gas Valve - Turn knob on gas
valve clockwise
to OFF. Do not force. See figure
4.
7 - Wait five minutes to clear out any gas. If you then smell
gas, STOP! Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's instrucĆ
tions. If you do not smell gas go to next step.
8 - White Rodgers 36E Gas Valve - Switch gas valve lever to
ON. See figure 3.
Page 4
NOTE - When unit is initially started, steps 1 through 11
may need to be repeated to purge air from gas line.
12 - If the appliance will not operate, follow the instructions
Turning Off Gas to the Unit" and call your service techĆ
nician or gas supplier.
Turning Off Gas to the Unit
1 - Set the thermostat to the lowest setting.
2 - Turn off all electrical power to the unit if service is to be
performed.
3 - Remove the upper access panel.
4 - White Rodgers 36E Gas Valve - Switch gas valve leĆ
ver to OFF.
Honeywell VR8205 Gas Valve - Turn knob on gas
valve clockwise
to OFF. Do not force.
5 - Replace the upper access panel.
Filters
This unit is not equipped with a filter or rack. A field-proĆ
vided, high-velocity filter is required to ensure proper unit
operation.
A filter must be in place any time the unit is operating.
Maintenance
A qualified service technician should inspect the complete
system each season (heating and cooling). The following
maintenance procedures should only be conducted by a
qualified service technician. Do not attempt to service
the unit in any way.
WARNING
ELECTRICAL SHOCK, FIRE,
OR EXPLOSION HAZARD.
Failure to follow safety warnings exactly could result
in dangerous operation, serious injury, death or
property damage.
Improper servicing could result in dangerous operaĆ
tion, serious injury, death, or property damage.
Before servicing, disconnect all electrical power to
furnace.
When servicing controls, label all wires prior to disĆ
connecting. Take care to reconnect wires correctly.
Verify proper operation after servicing.
Inspect the furnace return air duct connection. The duct
must be sealed to the furnace and it must terminate outside
the space containing the furnace.
Inspect the physical support of the furnace to guarantee
that it is sound. The support must not sag and must not
have cracks or gaps around the base of the furnace. There
must be a seal between the furnace base and the support.
During a seasonal check, the service technician will inĆ
spect the indoor blower and the burner flames along with
the venting system.
Blower
Check blower wheel for any debris and clean it, if necesĆ
sary. The blower motor is pre-lubricated for extended bearĆ
ing life. No further lubrication is needed.
WARNING
The blower access panel must be securely in place
when the blower and burners are operating. Gas
fumes, which could contain carbon monoxide, can
be drawn into living space resulting in personal injuĆ
ry or death.
Burner Flame
CAUTION
To ensure proper operation, a qualified technician
should annually check the burner flame.
Venting System
WARNING
Service Reminder
Asphyxiation Hazard
The exhaust vent for this furnace must be securely
connected to the furnace flue collar at all times.
For your safety and to fulfill the terms of the limited
warranty, a qualified service technician must annualĆ
ly inspect this furnace and its vent system.
Annually (before heating season) inspect furnace venting
system, vent cap, heat exchanger and burners for corroĆ
sion, deterioration, or deposits of debris. Remove any obĆ
structions.
Inspect thefurnace venting system to make sure it is in
place, physically sound and without holes, corrosion, or
blockage. The vent connector must be correctly posiĆ
tioned and sloped upward. The vent connector must be
physically sound, without holes or excessive corrosion.
Page 5
Call your Lennox service technician if the unit will not operĆ
ate. Before calling, always check the following to be sure
service is required.
1 - Check that electrical disconnect switches are ON.
2 - Check room thermostat for proper setting.
3 - Replace any blown fuses or reset circuit breakers.
4 - Gas valve should be ON.
5 - Air filter should not be plugged, which wil limit air flow.
6 - Is gas turned on at meter?
7 - Is manual main shut-off valve open?
Record the model and serial number of the furnace. These
numbers are on the unit nameplate, which is located below
the burners.
Serial Number
________________________________
Model Number ________________________________
Safety Precautions
If you discover any of the following, shut down your
unit and contact a Lennox dealer for an inspection by a
qualified technician.
If you repeatedly hear any new or unfamiliar sounds
while your unit is operating, there may be a problem. For
example, poorly performing burners can produce unfaĆ
miliar noises.
D If you smell any unusual odors, your unit may be operatĆ
ing improperly. For example, units can give off unfamilĆ
iar odors if components are required to operate in abĆ
normal conditions.
D Look for visible signs of a malfunctioning unit. Examples
include unusual amounts of condensate on windows inĆ
side your house, visibly burnt components or unusual
dirt or rust accumulations on the vent pipe or in the unit.
D If you experience headache, nausea, fatigue, or dizziĆ
ness, the cause could be exposure to carbon monoxide
gas. This is often misdiagnosed as the flu because
symptoms are similar. If you suffer from flu-like sympĆ
toms that are exaggerated at home, but seem to subĆ
side while you are away from the house, exposure to
carbon monoxide could be the cause.
Your vigilance may pay off in early detection of a problem
before either personal injury or property damage occurs.
Do not hesitate to contact a qualified service technician as
an investment in your well being.
D
Planned Service
You should expect a service technician to check the followĆ
ing items during an annual inspection. Power to the unit
must be shut off for the service technician's safety.
Page 6
Fresh air grilles and louvers (on the unit and in the room
where the furnace is installed) - Must be open and unobĆ
structed to provide combustion air.
Burners - Must be inspected for rust, dirt, or signs of water.
Vent pipe - Must be inspected for signs of water, damaged
or sagging pipe, or disconnected joints.
Unit appearance - Must be inspected for rust, dirt, signs
of water, burnt or damaged wires, or components.
Blower access door - Must be properly in place and proĆ
vide a seal between the return air and the room where the
furnace is installed.
Return air duct - Must be properly attached and provide
an air seal to the unit.
Operating performance - Unit must be observed during
operation to monitor proper performance of the unit and the
vent system.
Combustion gases - Flue products must be analyzed and
compared to the unit specifications.
Problems detected during the inspection may make it necĆ
essary to temporarily shut down the furnace until the items
can be repaired or replaced.
Pay attention to your furnace. Situations can arise beĆ
tween annual furnace inspections that may result in unsafe
operation. For instance, items innocently stored next to the
furnace may obstruct the combustion air supply. This could
cause incomplete combustion and the production of carĆ
bon monoxide gas.
Repair Parts List
The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model
number listed on the CSA International nameplate -- Example: G60UH(X)-36A-070-4.
Heating Parts
Cabinet Parts
Upper access panel
Flame Sensor
Blower panel
Heat exchanger assembly
Top cap
Gas manifold
Control Panel Parts
Two-speed combustion air inducer
Transformer
Two-stage gas valve
Two-stage SureLight® board
Main burner cluster
Door interlock switch
Main burner orifices
Circuit breaker
Pressure switch
Ignitor
Blower Parts
Primary limit control
Blower wheel
Flame rollout switch
Blower housing
Secondary limit
Motor
Capacitor
Motor mounting frame
Blower housing cutoff plate
Page 7